Shipping pallet and/or deck useful for such

ABSTRACT

A pallet 1 for carrying a load and be lifted by tines of a forklift is disclosed. The pallet 1 comprises a planar deck 10 for receiving a load thereon and a chassis below the deck for supporting the deck. The chassis comprises a plurality of hollow beams 112 of constant quadrilateral cross section in a grid formation to act in bending to assist in pallet load support. The beams 112 span parallel to the plane of the deck 10 and each oriented with vertical sidewalls facing perpendicular to the plane of the deck 10 and horizontal sidewalls facing parallel to the plane of the deck 10. At each intersection of two beams of the grid a first of the two beams has both of its vertical sidewalls removed to allow a second of the two beams to pass through the first beam.

FIELD OF THE INVENTION

The present invention relates to a shipping pallet and/or a deck usefulfor such.

BACKGROUND OF THE INVENTION

Shipping pallets for storing and transporting goods are primarily of atwin deck construction made from timber panels and beams. The top andbottom of the pallets are usually defined by wooden panels arranged in aparallel manner and that in concert act to provide the pallet as alaminate structure. This provides the pallet with high load bearingstrength in bending and torsion. Being made from wood, such pallets arerelatively cheap. They are usually designed to be able to receive thetines of a forklift to be lifted by the forklift when carrying a load.

However wooden shipping pallets have several disadvantages.

One disadvantage occurs in cross-border shipping of goods carried onsuch pallets. Being made from wood, regulations in some countriesrequire the wood to be fumigated before being allowed to leave theseaport or airport of arrival and enter the country. This can beexpensive and time consuming. If left untreated microbes may grow on/inthe wooden pallets and this can be unhygienic.

Another disadvantage is that wooden pallets can absorb water and becomeheavy and weaker as a result. Wooden pallets are also very susceptibleto impact damage. Leader board damage from forklifts driving too fastinto the pallets is a common cause of failure.

Another disadvantage is that their transport, for return to origin forexample, can be cost prohibitive and as such, the wooden pallets areoften discarded after one use. The twin deck format of such a palletdoes not lend itself to economic transport to origin due to the volumeof space it consumes. Pallets able to nest in a stacked configurationsolve this problem. U.S. Pat. Nos. 7,690,215 and 3,664,272 are examples.Nestable pallets such as this are typically single deck pallets. Twindecks usually prevent with nesting. But not having a twin deck“laminate” structure compromises the strength of such single deckpallets. Steel beams such as shown in U.S. Pat. No. 5,596,933 can beintroduced to increase load bearing strength of a single deck pallet. Ifhigher strength is desired, more/thicker steel beams can be added. Orthe beams can be of a higher second moment of inertia to resist out ofplane bending, this being best achieved by increasing the height of thebeams. More/thicker steel beams increases the weight of the pallet whichis undesirable because this adds to manufacturing and transport costs.Increasing the height of the beams reduces the compactness of stackednested pallets which can increase storage and/or return shipping costs.

Pallets may be stored in storage racks that do not have a deck butinstead two parallel pallet support rails. Typically, the pallets aresupported on the two parallel rails of the storage rack, at two opposededges of the pallets. Storage racks may come in two formats, the firstbeing a drive thought format where pallets are loaded sequentially ontwo rails from one end of the rails and a second being standard rackingwhere the pallets are loaded onto the rails lateral to the raildirection by being lowered onto the rails. The load on top of the palletcauses bending of the pallet between two rails. The pallet hence needsto be strong in bending to resist collapse under load. A single deckpallet whilst better suited for nested stacking with like pallets may beweaker in bending than a twin deck pallet of similar weight and size. Inaddition, standard rack loading and unloading of single deck pallets canbe problematic. Tines of a forklift need a gap between the rails and thedeck of the pallet.

When pallets are designed to have a chassis with plurality of beams in agrid formation, excessive welding may be required at least at eachjunction or intersection of the beams. Also, a chassis with excessivewelding is not reliable and may not be too strong as there is a risk ofcracks being formed at the welded portion or any other damage that cantypically occur at the wielded portion especially due to fatigue or dueto load or overload of the pallet. Even if the beams in a grid formationare non-metallic beams, excessive securement/bonding means (e.g. screws,nails, glues etc.) may be required at each junction or intersection ofthe beams. Cracks, breakage and/or other damages can typically occur tothe securement/bonding means and/at the such portion of the chassisespecially due to fatigue or due to load or overload of the pallet. Thebeam(s) can also accidently disengage from the rest of the pallet and/orfall due to fatigue or due to load or overload of the pallet.

OBJECT OF THE INVENTION

It is an object of the present invention to provide a shipping palletthat addresses at least some of the above-mentioned disadvantages and/orwhich will provide users with a useful choice.

STATEMENTS OF THE INVENTION

In a one aspect, there is provided a pallet for carrying a load and isable to be lifted by tines of a forklift, the pallet comprising a planardeck for receiving a load thereon and a chassis below the deck forsupporting the deck, the chassis comprising a plurality of hollow beamsorthogonal hollow beams of constant quadrilateral cross section in agrid formation to act in bending to assist in pallet load support, thebeams spanning parallel to the plane of the deck and each oriented withvertical sidewalls facing perpendicular to the plane of the deck andhorizontal sidewalls facing parallel to the plane of the deck,

wherein at intersections of two beams of the grid a first of said twobeams has both of its vertical sidewalls removed to allow a second ofsaid two beams to pass through the first beam.

In one embodiment, the beam with the sidewalls removed at theintersection has at least some of its bottom horizontal sidewallcontinuous over the intersection and parallel and preferably adjacent,and touches the bottom horizontal sidewall of the beam that passesthrough the first mentioned beam.

In one embodiment, the beam with the sidewalls removed at theintersection has at least some of its top horizontal sidewall continuousover the intersection and parallel and preferably adjacent, and touchesthe top horizontal sidewall of the beam that passes through the firstmentioned beam.

In one embodiment, the beam that passes through the first mentioned beamhas no cut-outs across of adjacent the intersection.

In one embodiment, the beam that passes through the first mentioned beamis of a constant cross section across and adjacent the intersection.

In one embodiment, the beam that passes through the first mentioned beamis welded to the first mentioned beam at regions where sidewalls of thetwo beams are adjacent each other.

In one embodiment, the beam that passes through the first mentioned beamis welded to the first mentioned beam at regions where sidewalls of thetwo beams are adjacent each other, other than at the bottom horizontalsidewalls.

In one embodiment, the beams are square or rectangular in cross section.

In one embodiment, the height of the beams defines substantially thethickness of the deck.

In one embodiment, at least one of the beams is made from a sheet metal.

In one embodiment, all said beams are made from a sheet metal.

In one embodiment, at least one beam is roll formed from a sheet metal.

In one embodiment, all said beams are roll formed from sheet metal.

In one embodiment, the sheet metal is no thicker than 1.8 mm thick.

In one embodiment, the sheet metal is about 1 mm thick.

In one embodiment, the pallet is square in shape.

In one embodiment, the pallet is rectangular in shape.

In one embodiment, the pallet is a shipping pallet.

In one embodiment, the grid is provided of at least two first set ofsaid beams extending between a first pair of opposed sides of the deckand at least two second set of said beams extending between a secondpair of opposed sides of the deck.

In one embodiment, at least one of the first and second set of beamsdefine a bottom portion of the deck at where the tines of the forkliftis able to engage to lift the pal let.

In one embodiment, a bottom of at least one of the beams is providedwith at least one of (a) an engineered profile (b) a double wall of saidsheet material.

In one embodiment, the engineered profile and/or the double wall of saidsheet material is provided in a manner to increase bend resistance atthe bottom of the beam.

In one embodiment, the engineered profile and/or the double wall of saidsheet material is provided in a manner to increase second moment ofinertia at the bottom of the beam.

In one embodiment, the engineered profile of said sheet material isprovided in a manner to increase bend resistance of the profile at thebottom of the beam.

In one embodiment, the engineered profile of said sheet material isprovided in a manner to increase second moment of inertia of the profileat the bottom of the beam.

In one embodiment, the engineered profile of said sheet material isprovided in a manner to increase second moment of inertia of the profileat the bottom of the beam.

In one embodiment, the first set of beams are of the samecross-sectional profile.

In one embodiment, the second set of beams are of the samecross-sectional profile.

In one embodiment, the first set of beams are at least 700 m long.

In one embodiment, the first set of beams are at least 800 m long.

In one embodiment, the first set of beams are at least 900 m long.

In one embodiment, the first set of beams are at least 1000 m long.

In one embodiment, the first set of beams are at least 1100 m long.

In one embodiment, the first set of beams are at least 1200 m long.

In one embodiment, the second set of beams are at least 700 m long.

In one embodiment, the second set of beams are at least 800 m long.

In one embodiment, the second set of beams are at least 900 m long.

In one embodiment, the second set of beams are at least 1000 m long.

In one embodiment, the second set of beams are at least 1100 m long.

In one embodiment, the second set of beams are at least 1200 m long.

In one embodiment, the first set of beams are no longer than 800 m long.

In one embodiment, the first set of beams are no longer than 900 m long.

In one embodiment, the first set of beams are no longer than 1000 mlong.

In one embodiment, the first set of beams are no longer than 1100 mlong.

In one embodiment, the first set of beams are no longer than 1200 mlong.

In one embodiment, the second set of beams are no longer than 800 mlong.

In one embodiment, the second set of beams are no longer than 900 mlong.

In one embodiment, the second set of beams are no longer than 1000 mlong.

In one embodiment, the second set of beams are no longer than 1100 mlong.

In one embodiment, the second set of beams are no longer than 1200 mlong.

In one embodiment, the beams of at least one of the first and second setof beams are quadrilateral in cross section and the engineered profileis a flange of said sheet metal extending into the interior or the beam.

In one embodiment, beams comprise of both a single ply of said sheetmaterial wall construction and double ply of said sheet material wallconstruction.

In one embodiment, beams comprise of both a single ply of said sheetmaterial wall construction and double ply of said sheet material wallconstruction at a lower region of the beam.

In one embodiment, a plurality of props extends downwardly from the deckto allow the pallet to be stably supported on a horizontal surface suchas a ground, a deck or a similar or identical pallet.

In one embodiment, the props are formed (preferably integrally formed)as a part of a top panel for the deck.

In one embodiment, the pallet is able to be edge supported on parallelrails of a storage rack.

In one embodiment, the pallet is a single deck pallet.

In one embodiment, the pallet is able to nest with an identical palletin a stacked condition.

In one embodiment, the pallet comprises four corners that are chamferedcorners.

In one embodiment, a shock absorber is provided at each corner of thepallet.

In one embodiment, the shock absorbers are provided by rubber blocks.

In one embodiment, the deck of the pallet is rectangular and is 1200 mmin length and 1000 mm in breadth.

In one embodiment, total weight of the pallet is approximately 17 kg.

In one embodiment, total weight of the pallet is 30 kg or less,preferably 25 kg or less, preferably 23 kg or less.

In one embodiment, the beams are intermediate beams.

In one embodiment, at each grid or intersection of two beams, thewelding occurs at the vertical sidewalls of the beams.

In one embodiment, at each grid or intersection of two beams, thewelding occurs only at the vertical sidewalls of the beams.

In one embodiment, at each grid or intersection of two beams, thewelding occurs at the vertical sidewalls and only one of the horizontalsidewalls of the beams.

In one embodiment, at each grid or intersection of two beams, no weldingoccurs at the horizontal sidewalls of the beams.

In one embodiment, each of the beams is spaced apart (or spaced) fromeach of the sides deck that is parallel to a longitudinal axis alongwhich that beam extends.

In one embodiment, each corner of the chassis is secured with a cornerbracket.

In one embodiment, each corner bracket is L-shaped.

In one embodiment, each corner bracket is secured with the chassis bywelding.

In one embodiment, welding occurs at each (or at least one) intersectionof two beams.

In one embodiment, at each (or at least one) intersection of two beams,welding occurs at only the horizontal sidewalls of the beams.

In one embodiment, at each (or at least one) intersection of two beams,welding occurs at only the vertical sidewalls of the beams.

In one embodiment, at each (or at least one) intersection of two beams,welding occurs at both the horizontal and vertical sidewalls of thebeams.

In one embodiment, at each (or at least one) intersection of two beams,welding occurs only at one of the horizontal sidewalls of the beams.

In one embodiment, at each (or at least one) intersection of two beams,welding occurs only at one of the horizontal sidewalls of the beams.

In one embodiment, welding occurs at the engineered profile of the beamor beams.

In one embodiment, welding occurs below the engineered profile of thebeam or beams.

In one embodiment, welding occurs above the engineered profile of thebeam or beams.

In one embodiment, welding occurs at each (or at least one) portionwhere two beams contact each other.

In one embodiment, at each (or at least one) portion where two beamscontact each other, welding occurs at only the horizontal sidewalls ofthe beams.

In one embodiment, at each (or at least one) portion where two beamscontact each other, welding occurs at only the vertical sidewalls of thebeams.

In one embodiment, at each (or at least one) portion where two beamscontact each other, welding occurs at both the horizontal and verticalsidewalls of the beams.

In one embodiment, at each (or at least one) portion where two beamscontact each other, welding occurs only at one of the horizontalsidewalls of the beams.

In one embodiment, at each (or at least one) portion where two beamscontact each other, welding occurs only at one of the horizontalsidewalls of the beams.

In one embodiment, the horizontal surface of at least one or each beamthat is distal from the deck comprises a longitudinally extending slotextending between two ends of said at least one or each beam. In oneembodiment, welding occurs in spaced apart configuration between alongthe longitudinally extending slot.

In another aspect, there is provided a pallet for carrying a load and isable to be lifted by tines of a forklift, the pallet comprising a planardeck for receiving the load thereon and a chassis below the deck forsupporting the deck, the deck having a top portion for supporting theload and a bottom portion opposite the top portion, at least four sides,the at least four sides comprising a first pair of opposed sides and asecond pair of opposed sides, the chassis being in a grid formation andcomprising a first set of at least two spaced apart and parallel beamsextending between the first pair of opposed sides of the deck but spacedapart from the second pair of opposed sides of the deck, and a secondset of at least two spaced and parallel beams extending between thesecond pair of opposed sides of the deck but spaced apart from the firstpair of opposed sides of the deck,

wherein the first set of beams are orthogonal to the second set ofbeams,

wherein at each intersection of two beams of the grid a first of saidtwo beam has a notch or a slot to allow a second beams to pass throughthe first beam.

In one embodiment, the beams are hollow beams of constant quadrilateralcross section, the beams spanning parallel to the plane of the deck andeach oriented with vertical sidewalls facing perpendicular to the planeof the deck and horizontal sidewalls facing parallel to the plane of thedeck.

In one embodiment, the notch or the slot is formed by removing both thevertical sidewalls of the said first beam.

In one embodiment, the slot is formed by removing both of its verticalsidewalls removed and one of the horizontal sidewalls of said firstbeam, one of the horizontal sidewalls being proximal to the deck.

In one embodiment, the pallet and/or deck is of a kind as hereinbeforeor hereinafter described.

In a further aspect, there is provided a single deck pallet comprising:

a deck having a top portion for supporting a load and a bottom portionopposite the top portion, at least four sides, the at least four sidescomprising a first pair of opposed sides and a second pair of opposedsides, the bottom portion comprising a chassis, the chassis comprising aplurality of orthogonal hollow beams of constant quadrilateral crosssection in a grid formation to act in bending to assist in pallet loadsupport, the beams spanning parallel to the plane of the deck and eachoriented with vertical sidewalls facing perpendicular to the plane ofthe deck and horizontal sidewalls facing parallel to the plane of thedeck,

wherein at intersections of two beams of the grid a first of said twobeams has both of its vertical sidewalls removed to allow a second ofsaid two beams to pass through the first beam.

In one embodiment, the grid formation is provided of at least two firstset of said beams extending between the first pair of opposed sides ofthe deck and at least two second set of said beams extending between asecond pair of opposed sides of the deck.

In one embodiment, at least one of the first and second set of beamsdefine a bottom portion of the deck at where the tines of the forkliftis able to engage to lift the pal let.

In one embodiment, the pallet and/or deck is of a kind as hereinbeforeor hereinafter described.

In a yet further aspect, there is provided a pallet as defined in anyone of the above statements, wherein the pallet comprises a plurality ofdiscretely distributed primary props dependent from the deck andprojecting below a or the bottom portion of the deck to aid insupporting the pallet on a surface.

In one embodiment, the pallet is capable of being edge supported byspaced apart parallel rails of a storage rack.

In one embodiment, the pallet further comprises a plurality ofdiscretely distributed primary props dependent from the deck andprojecting below the bottom portion of the deck to support the pallet ona surface.

In one embodiment, the pallet further comprises a plurality of discretesecondary props for supporting the pallet on the rails of the storagerack, each secondary prop projecting below the bottom portion of thedeck and being provided intermediate of a primary prop and an associatedat least one of the four sides of the deck to elevate the bottom portionof the deck above the rack such as to accommodate the passage of aforklift tine between a rail of the rack and the deck of the pallet.

In one embodiment, both the primary props and secondary props are spacedapart so as to allow two tines of a forklift to pass between both theprimary props and secondary props to come to bear on the bottom portionof the deck.

In one embodiment, width of the deck between the or a first pair ofopposed sides of the deck is greater than a gap between the two spacedapart parallel rails of the storage rack upon which the pallet is ablebe supported on the secondary props.

In one embodiment, the plurality of primary props is spaced inwardlyadjacent and along the first pair of opposed sides to allow the primaryprops to sit intermediate of the rails of a storage rack.

In one embodiment, the primary props provided along each of the firstpair of opposed sides are spaced apart between the first pair of opposedsides such that said primary props may sit intermediate of the rails ofa storage rack.

In one embodiment, the primary props are provided along each of thefirst pair of opposed sides are spaced apart so as to prevent either ofthe first pair of opposed sides from falling off the rails of thestorage rack due to a lateral movement of the pallet relative to therails when the pallet is supported on the rails by the secondary props.

In one embodiment, the primary props provided adjacent each of the firstpair of opposed sides are spaced between the first pair of opposed sidessuch that, when the rack is supported on the rails by the secondaryprops, the primary props adjacent each of the first pair of opposedsides engage with the rails to substantially prevent movement of thepallet lateral of the rails.

In one embodiment, the primary props provided along each of the firstpair of opposed sides comprise a lead-in such that each primary proptapers away from the adjacent one of the first pair of opposed sides asthe primary prop projects away from the base of the deck.

In one embodiment, the primary props each comprise a projection from thebase of the deck, each projection at least in part tapering inwards fromeach of the first pair of opposed sides as the primary props extendsfrom the base of the deck.

In one embodiment, the plurality of primary props is spaced adjacent andalong the or a second pair of opposed sides, so as to allow the primaryprops to sit intermediate of each respective second side and the primaryprops adjacent each second side.

In one embodiment, the primary props provided along each of a or thesecond pair of opposed sides are spaced apart so as to prevent either ofthe second pair of opposed sides from falling off the rails of thestorage rack due to a lateral movement of the pallet relative to therails when the pallet is edge supported on the rails by portions of thedeck proximate to each of the second pair of opposed sides.

In one embodiment, the primary props provided along each of the secondpair of opposed sides comprise a lead-in such that the primary proptapers away from the adjacent one of the second pair of opposed sides asthe primary prop projects away from the base of the deck.

In one embodiment, a distance the primary props project away from thebottom of the deck is greater than a distance the secondary propsproject from the deck.

In one embodiment, the primary props provided adjacent each of thesecond pair of opposed sides are spaced between the second pair ofopposed sides such that when the rack is edge supported on the rails,the primary props adjacent each of the second pair of sides engage withthe rails to substantially prevent movement of the pallet lateral of therails.

In one embodiment, the primary props provided along each of the secondpair of opposed sides comprise a lead-in such that each primary proptapers away from the adjacent one of the second pair of opposed sides asthe primary prop projects away from the base of the deck.

In one embodiment, the primary props adjacent each of the first pair ofopposed sides of the deck are inset from their associated side of thedeck.

In one embodiment, the plurality of primary props is distributed in agrid format from the deck.

In one embodiment, the pallet comprises at least four primary props,wherein four of the at least four primary props are provided adjacent toand at one end of each of the two opposed sides.

In one embodiment, the deck comprises four corners at the intersectionof the first pair of sides and second pair of sides, and four primaryprops are provided at or towards each of the four corners.

In one embodiment, the deck is or comprises a quadrilateral shape.

In one embodiment, the deck is or comprises a rectangular or squareshape.

In one embodiment, the deck comprises one or more rounded or chamferedcorners.

In one embodiment, the plurality of primary props is inset from each ofthe first pair of opposed sides.

In one embodiment, the plurality of primary props are spaced inwardlyadjacent and along both the first pair of opposed sides and second pairof opposed sides.

In one embodiment, the secondary props are provided only intermediate ofprimary props located adjacent and along the first pair of opposedsides.

In one embodiment, the secondary props are not provided intermediate ofprimary props located adjacent and along the second pair of opposedsides.

In one embodiment, the number of secondary props correspond to thenumber of primary props provided directly adjacent each of the firstpair of opposed sides of the deck.

In one embodiment, the pallet comprises at least four secondary props,wherein four of the at least four secondary props are associated withfour primary props provided adjacent to and at an end of each of thefirst set of opposed sides.

In one embodiment, the width of the secondary props along the directionof the first set of opposed sides is less than the width of the primaryprops along the direction of the first set of opposed sides.

In one embodiment, at least some of the secondary props are dependentfrom the deck.

In one embodiment, at least some of the secondary props are dependent onat least some of the primary props.

In one embodiment, the secondary props are dependent from primary propslocated adjacent each of the first pair of opposed sides.

In one embodiment, the pallet may be supported on the rails of the rackon the plurality of secondary props, such that a forklift may access thepallet in a direction substantially perpendicular to the rails of therack.

In one embodiment, the pallet may be supported on the second set ofopposed sides of the deck, such that a forklift may access the pallet ina direction substantially parallel to the rails of the rack.

In one embodiment, the deck between the primary props and each side ofthe second pair of opposed sides comprises a ledge, such that a palletsupported on the second side of opposed sides is supported on the ledgeof the deck.

In one embodiment, the deck comprises a top panel, and dependent fromthe top panel are the primary props.

In one embodiment, the primary props are integrally formed with the toppanel of the deck.

In one embodiment, the top panel comprises a plurality of primary hollowdepressions corresponding to the number of primary props and shaped tonest with the primary props of another pallet, preferably ashereinbefore or hereinafter described.

In one embodiment, the nesting comprises an at least partial receivingof the primary props of another pallet within the plurality of primaryhollow depressions of the top panel.

In one embodiment, the top panel comprises a plurality of secondaryhollow depressions corresponding to the number of secondary props andshaped to nest with the secondary props of another pallet, preferablyanother single deck pallet, preferably as hereinbefore or hereinafterdescribed.

In one embodiment, the nesting comprises an at least partial receivingof the secondary props of another pallet within the plurality ofsecondary hollow depressions of the top panel.

In one embodiment, the primary depressions comprise one or more tertiaryprops projecting towards the deck of the pallet such that the deck ofthe pallet and the deck of a nested pallet remain separated so as toallow the tines of a forklift to pass between decks.

In another aspect, there is provided a system of a pallet rack and apallet as hereinbefore or hereinafter described, wherein the pallet is asingle deck pallet that is either

supported on the rails of the pallet rack on the plurality of secondaryprops, the opposed sides of the pallet being substantially parallel withthe rails of the rack, or

supported on the opposed ends of the deck, the opposed ends of thepallet being substantially parallel with the rails of the rack.

In one embodiment, the pallet is of a kind as described above.

In yet another aspect, there is provided a plurality of pallets ashereinbefore or hereinafter described, the pallets being single deckpallets provided in a nested condition relative to each other.

In one embodiment, secondary props are provided along all sides of thedeck.

In one embodiment, the spacing of parallel beams between two adjacentprimary props in a first orthogonal direction is different to thespacing of parallel beams between two adjacent props in a secondorthogonal direction.

In one embodiment, the spacing between beams and adjacent primary propsis the same for beams between all adjacent props in said orthogonaldirection.

Other aspects of the invention may become apparent from the followingdescription which is given by way of example only and with reference tothe accompanying drawings.

In this specification where reference has been made to patentspecifications, other external documents, or other sources ofinformation, this is generally for the purpose of providing a contextfor discussing the features of the invention. Unless specifically statedotherwise, reference to such external documents is not to be construedas an admission that such documents, or such sources of information, inany jurisdiction, are prior art, or form part of the common generalknowledge in the art.

For purposes of the description hereinafter, the terms “upper”, “lower”,“right”, “left”, “vertical”, “horizontal”, “top”, “bottom”, “lateral”,“longitudinal” and derivatives thereof shall relate to the invention asit is oriented in the drawing figures. However, it is to be understoodthat the invention may assume various alternative variations, exceptwhere expressly specified to the contrary. It is also to be understoodthat the specific devices illustrated in the attached drawings anddescribed in the following description are simply exemplary embodimentsof the invention. Hence, specific dimensions and other physicalcharacteristics related to the embodiments disclosed herein are not tobe considered as limiting.

It is acknowledged that the term “comprise” may, under varyingjurisdictions, be attributed with either an exclusive or an inclusivemeaning. For the purpose of this specification, and unless otherwisenoted, the term ‘comprise’ shall have an inclusive meaning, allowing forinclusion of not only the listed components or elements, but also othernon-specified components or elements. The terms ‘comprises’ or‘comprised’ or ‘comprising’ have a similar meaning when used in relationto the system or to one or more steps in a method or process.

As used hereinbefore and hereinafter, the term “and/or” means “and” or“or”, or both.

As used hereinbefore and hereinafter, “(s)” following a noun means theplural and/or singular forms of the noun.

When used in the claims and unless stated otherwise, the word ‘for’ isto be interpreted to mean only ‘suitable for’, and not for example,specifically ‘adapted’ or ‘configured’ for the purpose that is stated.

For the purposes of this specification, the term “plastic” shall beconstrued to mean a general term for a wide range of synthetic orsemisynthetic polymerization products, and generally consisting of ahydrocarbon-based polymer.

For the purpose of this specification, where method steps are describedin sequence, the sequence does not necessarily mean that the steps areto be chronologically ordered in that sequence, unless there is no otherlogical manner of interpreting the sequence.

The entire disclosures of all applications, patents and publications,cited above and below, if any, are hereby incorporated by reference.

For the purposes of this specification, the term “plastic” shall beconstrued to mean a general term for a wide range of synthetic orsemisynthetic polymerization products, and generally consisting of ahydrocarbon-based polymer. PLA is also envisaged.

For the purpose of this specification, where method steps are describedin sequence, the sequence does not necessarily mean that the steps areto be chronologically ordered in that sequence, unless there is no otherlogical manner of interpreting the sequence.

To those skilled in the art to which the invention relates, many changesin construction and widely differing embodiments and applications of theinvention will suggest themselves without departing from the scope ofthe invention as defined in the appended claims. The disclosures and thedescriptions herein are purely illustrative and are not intended to bein any sense limiting.

BRIEF DESCRIPTION OF THE DRAWINGS

Preferred embodiments of the invention will be described by way ofexample only and with reference to the drawings, in which:

FIG. 1 shows a perspective view of a pallet of a preferred form of thepresent invention shown from above,

FIG. 2 is a bottom perspective view of the pallet of FIG. 1,

FIG. 3 is a top plan view of the pallet of FIG. 1,

FIG. 4 is a bottom plan view of the pallet of FIG. 1,

FIG. 5 is a side view of the pallet of FIG. 1,

FIG. 6 is an end view of the pallet of FIG. 1,

FIG. 7 shows two pallets nested in a stacked configuration in across-sectional view,

FIG. 8 shows a cross sectional perspective view of the pallet of FIG. 1,

FIG. 9A shows a pallet carrying goods stored in standard racking onparallel rails of the rack, seen in front view,

FIG. 9B is a view in direction AA of FIG. 9A,

FIG. 10A shows a pallet of a kind as shown in FIG. 1 shown on drivethrough racking, the pallet carrying goods,

FIG. 10B shows a view in direction BB of FIG. 10A,

FIG. 11A shows a side view of a variation of a pallet,

FIG. 11B shows a side view of a further variation of a pallet,

FIG. 11C shows a side view of yet a further variation of a pallet,

FIG. 12A shows an end view of a variation of a pallet,

FIG. 12B shows an end view of a variation of a pallet,

FIG. 12C shows an end view of a further variation of a pallet,

FIG. 13A shows a bottom view of a pallet according to an embodiment ofthe present invention having perimeter beams and props,

FIG. 13 B shows a bottom view of an embodiment of a pallet according toanother embodiment of the present invention having a props but noperimeter beam,

FIG. 13 C shows a bottom view of a pallet according to yet anotherembodiment of the present invention having perimeter beams but no props,

FIG. 13 D shows a bottom view of an embodiment of a pallet having noprops and no perimeter beam,

FIG. 13 E shows a tine of a forklift for lifting a pallet of FIG.13A-FIG. 13D,

FIG. 14 shows a bottom perspective view of the pallet of FIG. 13A,

FIG. 15 shows a sectional perspective view of the pallet of FIG. 13D,

FIG. 15A is a side view of a deck of a pallet and a forklift tine,

FIG. 15B is a side view of a deck of a pallet end supported on railsshowing deflection of the deck when under loading,

FIG. 15C is a side view of a deck of a pallet showing uneven loading andthe resulting uneven curvature of the deck that may result from suchloading,

FIG. 16 shows a top plan view of the metal framework of one example of achassis of the deck for use in a pallet of the present invention,

FIG. 16A shows a detailed view of section A of FIG. 16,

FIG. 17 shows a bottom plan view of the chassis of FIG. 16,

FIG. 17A shows a detailed view of section B of FIG. 17,

FIG. 18A shows one example of a beam that may be used in or to definethe chassis of the of the deck for use in a pallet of the presentinvention,

FIG. 18B shows a top plan view of the beam of FIG. 18A,

FIG. 18C shows a side view of the beam of FIG. 18A,

FIG. 18D shows another example of a beam that may be used to define thechassis of the deck for use in the pallet of the present invention,

FIG. 18E shows a side view of the beam of FIG. 18D,

FIG. 18F shows an end view of the beam of FIG. 18D. This is can also beconsidered as a cross sectional view of the beam of FIG. 18A or 18D in aplane that is orthogonal to the longitudinal axis of the beam at alocation that does not comprise a notch or a slot,

FIGS. 19A to 19B are bottom partial perspective views showing two beamsbeing coupled at the notch of one of the two beams at an intersection orgrid,

FIG. 19C is a top perspective view of two beams showing the two beamsbeing be coupled at the slot of one of the two beams at an intersectionor grid,

FIG. 20A shows portions two beams at an intersection or grid wherewelding can occur,

FIG. 20B shows the horizontal wall of a beam being in tension when aload is applied to the beam,

FIG. 21A shows a bottom perspective view of the metal framework of oneexample of a chassis of the deck for use in a pallet of the presentinvention,

FIG. 21B is a bottom plan view of the chassis of FIG. 21A,

FIG. 21C shows a view in direction XX of the chassis of FIG. 21B,

FIG. 21D shows a view in direction YY of the chassis of FIG. 21B,

FIG. 21E is a top plan view of the chassis of FIG. 21A,

FIG. 22A shows a detailed view of section C of FIG. 21B,

FIG. 22B shows a detailed view of section D of FIG. 21B,

FIG. 22C shows a detailed view of section E of FIG. 21B,

FIG. 22D shows a detailed view of section F of FIG. 21B,

FIG. 22E shows a detailed view of section G of FIG. 21E,

FIG. 22F shows a detailed view of section H of FIG. 21E,

FIG. 22G shows a cross-sectional view along direction V-V of FIG. 21C,

FIG. 22H shows a cross-sectional view along direction ZZ of FIG. 21E,

FIG. 23A shows a perspective view of one of the beams of chassis of FIG.21A,

FIG. 23B shows an end view of the beam of FIG. 23A,

FIG. 23C shows a top plan view of the beam of FIG. 23A,

FIG. 23D is a side view of the beam of FIG. 23A,

FIG. 24A shows a perspective view of another one of the beams of chassisof FIG. 21A,

FIG. 24B shows an end view of the beam of FIG. 24A,

FIG. 24C shows a top plan view of the beam of FIG. 24A,

FIG. 24D is a side view of the beam of FIG. 24A,

FIG. 25 shows a corner bracket of the chassis of FIG. 21A.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

With reference to FIGS. 1 and 2 a single deck pallet 1 is shown. Thesingle deck pallet 1 is capable of being edge supported by spaced apartparallel rails of a storage rack. It is also capable of being lifted byforklift tines. The single deck pallet 1 may comprise of a deck 10(defining the plan shape) having a top 11 for supporting a load and abottom 12. The preferred construction and materials used for the deck isdescribed further below.

The deck 10 of the pallet 1 comprises at least 4 sides, which f includesthe first pair of sides oppose sides 13 and second pair of opposed sides14. The pallet can be edge supported along at least one pair of opposedsides of the deck. In most preferred forms the deck will be of asubstantially quadrilateral shape such as a rectangle or square shape.Furthermore, the deck may correspond to standardised sizes of palletscommonly used in industry.

In a preferred form the pallet is of a square or rectangular plan shapeand it may be of the following dimensions (with preferred total minimumload capacity in edge supporting mode shown) as examples:

-   -   600×800 (2000 kg)    -   1000×1200 (2000 kg)    -   1000×1000 (2000 kg)        Other deck sized may include:    -   1000×1200    -   1006×1206    -   1016×1219    -   1067×1067    -   1200×1200    -   1020×1200    -   1060×1200    -   1100×1100    -   1165×1165    -   1166×1242

In a preferred form, for example as shown in FIGS. 1 and 2, the majorityof the perimeter of the deck is formed to define a first pair of opposedsides 13 and second pair of opposed sides 14. The first and second pairsof opposed sides intersect with each other at four corners of the deck10. In some embodiments, the deck may comprise of one or more chamferedcorners (see FIG. 1). In addition, or alternatively, the corners of thedeck may also comprise impact absorbers such as rubberized covers (e.g.rubber blocks) or attachments for each of the corners.

The pallet may comprise of a plurality of discretely distributed primaryprops 15. A plurality of discretely distributed primary props 15 areshown in the view of FIG. 2. The plurality of primary props 15 arepreferably dependent from the deck 10 and project below the bottom 12 ofthe deck 10 to support the pallet on a surface such as the ground or astorage rack deck in a manner to support the deck in an elevated mannerabove the ground/storage rack deck. This ground clearance allowsforklift tines to pass under the deck and then lift the pallet at thedeck (by bearing onto the bottom 12 of the deck 10). All primary propspreferably project to an equal distance from the deck 10.

At least two primary props 15 are preferably located adjacent each edgeof the deck 10 so as to provide a stable platform for goods carried onthe deck when the pallet is supported on a ground or on another deck orany other horizontal or substantially horizontal surface. There mayhence be at least 4 primary props, one adjacent each corner of the deck.Further props may be provided along each edge and/or intermediate of theedge located props.

Preferably the primary props 15 have openings at their base to allow forliquid to flow through. The deck 10 preferably has air-holes. Preferablythe top panel or top surface is of one piece and may have an edge lip.It may be covered in an anti-slip coating.

As shown in FIGS. 1 and 2, the pallet 10 may further comprise of aplurality of discrete secondary props 16. In order to provide spacingsuch that two tines of a forklift may pass between both the primaryprops 15 and secondary props 16 and to come to bear on the bottom of thedeck, the primary props may be distributed in a grid format from thedeck. For example, one such grid format is shown in FIGS. 2 to 4,wherein nine primary props 15 project below the deck and are arrangedinto aligned rows and columns.

The primary props 15, and particularly the peripheral primary props,being those closest to a side or sides of the deck 10, may havepurposive spatial relationships to either or both of the first pair ofsides 13 and second pair of sides 14, as herein after described.

As shown in FIGS. 9A-9B and 10A-10B the secondary props 16 may, incertain conditions, be used for edge supporting the pallet 1 on therails 19 of a rack 17 so as to elevate the deck 10 above the rails 19.Such elevation allows forklift tines to pass through the gap between therails and the deck and then lift the pallet 1 by engaging the bottom ofthe deck 10. The racking system that may be used for accommodating apallet in this configuration is sometimes known as standard racking.

Each secondary prop 16 preferably projects below the bottom 12 of thedeck 10. They all preferably project to an equal distance from the deck10.

In a preferred form secondary props 16 are located near the ends of anadjacent edge to help provide a stable platform for goods carried on thepallet 1 when edge supported on standard rack rails.

In a plan view, the secondary props 16 are preferably each providedintermediate of a primary prop 15 and an adjacent one of the four sidesof the deck 10.

For example, as shown in FIGS. 1 and 2, a number of primary props 15 areprovided adjacent and along each of the first pair of sides 13. Each ofthe secondary props 16 are then provided intermediate of each of theseprimary props 15 and their respective one of the first pair of sides 13.In other embodiments the secondary prop 16 may be provided in theirintermediate configuration along either or both of the first pair ofsides 13 and second pair of sides 14.

Shown in FIGS. 3 and 4 are views from above and below the pallet 1,showing the top 11 of the deck 10, the bottom 12 of the deck 10, and theprimary props 15 and secondary props 16.

In a stored configuration when the secondary props 16 support the pallet10 on the rails 19 of a rack 17, the secondary props serve to elevatethe bottom 12 of the deck 10 above the rack 17 more specifically rails19 of the rack 17. This elevation of the bottom of the deck 10 is to beat least such as to accommodate the passage of a forklift tine between arail 19 of the rack 17 and the deck 10 of the pallet 1.

Shown in FIG. 5 is a side view of the pallet 1. The secondary props 16are shown in their preferred position intermediate of the outer primaryprops 15 and the first pair of sides 13. In some forms of pallet (notshown), secondary props 16 are also provided along each of the secondarypair of sides 14. However, in the preferred form, secondary props 16 arenot provided along each of the secondary pair of sides 14. Instead, aledge 20 of the bottom 12 of the deck 10 is provided between the primaryprops 15 and each of the second sides 14. This is shown for example inFIG. 10b and is so provided to make the pallet suitable fordrive-through racking as will hereinafter be described.

As seen in FIGS. 1 and 2, both the primary props 15 and secondary props16 are horizontally spaced apart so as to allow two tines 100 of aforklift spaced at distance D apart, to pass between both primary props15 and secondary props 16 to come to bear on the bottom 12 of the deck10. This spacing apart of the primary props and secondary props may be aspacing in either the direction of the length of the first pair of sides13 or second pair of sides 14. In a preferred form however thishorizontal spacing of the primary props and secondary props is in boththe direction of the first pair of sides 13 and the second pair of sides14 so that the pallet can be used as a 4-way pallet. In such aconfiguration, two tines of a forklift may be allowed to pass betweenboth the primary props and the secondary props and come to bear on thebottom of the deck when the tines of the forklift are introduced in adirection substantially perpendicular to either of the first pair ofsides 13, or to either of the second pair of sides 14.

In order to accommodate the secondary props 16, the primary props 15 maybe inset from each of the first pair of sides 13. This is particularlyin the configuration seen in FIGS. 1 and 2, where the secondary props 16are positioned intermediate of the primary props 15 and one of the firstpair of sides 13, but also directly between each primary prop 15 and itsadjacent portion of its associated one of the first pair of sides 13.

In some forms the secondary props 16 may be provided at differentpositions along the first pair of sides 13, such that they are notdirectly between a primary prop 15 and an adjacent portion of one of thefirst pair of sides 13.

In some embodiments the secondary props 16 may extend right up to theirrespective ones of the first pair of sides 13.

The secondary props 16 may be provided as dependent from either or bothof the deck 10 and the primary props 15. Three example configurations ofthe secondary props 16 are shown in FIGS. 11A to 11C. In FIG. 11A, thesecondary props 16 are dependent from, and potentially integrally formedwith, both of the deck 10 and primary props 15. In FIG. 11B, thesecondary props 16 are provided as dependent only from their associatedprimary props 15. In FIG. 11C, the peripheral secondary props 16 arealso to be provided in a specific relationship in relation to the secondpair of sides 14. The secondary props 16 are preferably at leastpartially nestable but may not be nestable.

The pallet 1 may be edge supported on the rails of a storage rack. Apreferred form of providing such edge support is by providing theprimary props 15 located along each of the second pair of sides 14 insetfrom their respective one of the second pair of sides in order toprovide a ledge 20. A view of a pallet 1 along the second pair of sides14 and showing the ledge 20 upon which the pallet may be edge supportedis shown in FIG. 10b . If the secondary props 16 are not provided in acorresponding location along the first pair of sides 13 to the primaryprops 15 then the secondary props 16 at either end of the first pair ofsides 13 may also need to be inset from the second pair of sides 14 inorder to provide the ledge 20 for this format of rack support.

In the preferred form the ledge 20 adjacent each second pair of sides 14allows the pallet to be edge supported along the length of the secondpair of sides on a pair of rails 19.

In a preferred embodiment the primary props 15 are inset from both ofthe first pair of sides 13 and second pair of sides 14, and thesecondary props 16 are at least in set from the second pair of sides 14.

The pallet 1 is able to be supported on rails of a rack, and the deck 10of the pallet is accessible at its bottom for lifting by a forklift,when the pallet is oriented either with its first pair of sides 13 orits second pair of sides 14 substantially parallel to the rails of astorage rack.

Views of a potential storage rack 17 with which the pallet 1 may be usedare shown in FIGS. 9A to 9B and 10A to 10B. As shown in these figures,the support rack 17 comprises a plurality of uprights 18 and a pluralityof associated parallel rails 19. The configurations shown in FIGS. 9 and10 are by way of example only, and any number of commonly usedvariations, such as variations in the height, width, and number of rowsof rails 19 of the support rack 17 may be provided within the scope ofthe invention.

A first racking configuration of a pallet 1 is shown in FIGS. 9A and 9B.In this configuration, the first pair of sides 13 are orientedsubstantially parallel to the rails 19 of the support rack. Whenoriented relative to the rails 19 in this manner, the pallet 1 issupported on the rails 19 by the secondary props 16.

When supported on the secondary props 16 as shown in FIGS. 9A and 9B, agap is to be provided between the rails 19 and the deck 10 of the palletsuch that the tines of a forklift may be accommodated between the deck10 and rails 19.

When supported on the secondary props 16, a pallet 1 may be accessibleby a forklift from the side of the rack, that is in a directionperpendicular to the elongate direction of the rails 19.

Accordingly, the depth of projection of the secondary props 16 away fromthe bottom 12 of the deck 10 may be selected according to theapplication, such as for forklift tines of different thicknesses, or fordifferent desired clearances for the forklift tines.

A second racking configuration is shown in FIGS. 10A and 10B. In thisconfiguration, the second pair of sides 14 of the pallet are orientedsubstantially parallel to the rails 19 of the support rack 17. Thepallet is supported on the rails 19 along the ledge 20 of the deck 10which is located adjacent to each of the second pair of sides 14. Anysecondary props 16 provided by the pallet 1 do not need to bear on therails in this storage configuration. When supported on a rack 17 withthe second pair of sides 14 substantially parallel with the rails 19,the pallet 1 is to be accessed by a forklift in a direction parallel tothe elongate direction of the rails 19, that is, in a direction alongthe length of the support rack 17.

Preferably the width of the deck 10 between either of the pair of sidesalong which the pallet is to be supported by the rails 19 is greaterthan the gap between the two spaced apart rails 19 of the storage rack17. For example, where the pallet is to be supported on the secondaryprops 16, the width of the deck 10 between the first pair of proposedsides 13 must be of greater width than the gap between the two parallelrails of the support rack 17. Similarly, if the pallet is to besupported on the ledges 20 of the deck 10, such that the second pair ofsides 14 are oriented substantially parallel to the rails 19, the widthof the deck 10 between the second pair of sides 14 must be greater thanthe gap between the rails 19.

Preferably in either supported orientation, the plurality of primaryprops are to be spaced inwardly adjacent and along at least one of thefirst pair of sides and second pair of sides, but preferably inwardlyadjacent and along both pairs of sides. Thus, the primary props 15 willsit intermediate of the rails 19 of the storage rack when the pallet issupported by the rails.

Particular spacing of at least the primary props 15 relative to therails 19 of a support rack 17 may also be desirable.

For the pallet configuration where it is edge supported at the ledges 20on the rails 19, the spacing of the peripheral primary props 15 alongthe first pair of sides 13 may be used to control the movement of thepallet lateral of the two rails 19 when the pallet is edge supported onthe rails. The primary props 15 are to sit intermediate of the rails 19.By providing the peripheral primary props 15 closer to their adjacentrail 19 than the gap between the rail and the outer edge 14 of the deck,the primary props may act to prevent the pallet from falling off therails due to restricting the lateral movement of the pallet on therails.

Similarly, the positioning of the primary props 15 along the second pairof sides 14 may be designed so as to limit the lateral movement of thepallet 1 relative to the rails 19 when the pallet is supported on thesecondary props 16.

An example configuration of the distribution of the primary props 15along the first pair of sides 13 so as to limit the lateral movement ofthe pallet on the rails 19 when the pallet 1 is edge supported on theledges 20 of the deck is shown in FIG. 10B.

The secondary props 16 may be located along all sides of the pallet 1.They are preferably located outwardly more of the primary props 15 butmay instead, at least in some instances be located inwardly of itsadjacent primary prop 15.

Similarly, an example embodiment showing the distribution of the primaryprops 15 along the second pair of sides 14 such as to limit the lateralmovement of the pallet 1 on the rails 19 when the pallet 1 is supportedon its secondary props 16 is shown in FIG. 9B.

In some forms the arrangement of the primary props along the first pairof sides and the second pair of sides may be such as to prevent thepallet from slipping off the rails on which it is supported. In otherforms, the spacing of the primary props may be act to lock the palletlaterally against the rails 19, in order to limit or even substantiallyprevent movement of the pallet lateral of the rails.

In order to accommodate the movement limiting relationship between theprimary props 15 and rails 19 yet to prevent undesired engagementbetween the primary props 15 and the rails 19 particularly when loadingone into the support rack 17 at least the peripheral portions of theprimary props 15 may be provided with a lead in. Such a lead in may becharacterized by the primary prop tapering away from the adjacent one ofthe first pair of sides 13 or second pair of sides 14 as the primaryprop projects away from the base of the deck. For example, see theembodiment of FIG. 2 wherein the primary props 15 about the periphery ofthe deck 10 comprise a lead in such that at least their portionsadjacent to the first pair of sides 13 and second pair of sides 14 taperaway from the sides of the deck as the primary props extend downward.

The distance that the primary props extend below the deck is preferablygreater than the distance the secondary props extend below the deck. Thesecondary prop distance may for example be 30 mm from the bottom of thedeck. The primary prop distance may for example be 95 mm.

In a preferred form the top 11 of the deck 10 may be defined by a toppanel that comprises a plurality of primary hollow depressions 21. Theseprimary hollow depressions 21 are to correspond to the number of props15, and to be shaped to nest with the primary props of another singledeck pallet. Such primary hollow depressions 21 are seen for example inFIG. 1.

A cross section through two pallets 1 shown in a nested configuration isseen in FIG. 7.

In order to provide for a more complete nesting of single deck palletsof the present invention within each other in a stacked condition, thetop panel of the deck of each pallet may further comprise a plurality ofsecondary hollow depressions 22 corresponding to the number and positionof the secondary props 16. The secondary hollow depressions 22 areshaped to nest with the secondary props of another single deck pallet.

Where the single deck pallets are to be nested together, it may bedesirable to limit the degree of nesting of the pallets with each othersuch that the tines of a forklift may still be able to be passed betweenthe decks of the pallets in order to separate them. To this end, eitheror both the primary hollow depressions 21 or secondary hollowdepressions 22, where present, may be provided with at least onetertiary prop 23. The tertiary props 23 according to one embodiment areshown in FIGS. 7 and 8. The tertiary props 23 extend from the base ofthe depressions upwardly towards the top 11 of the deck 10. The spacingof the decks of nested pallets from each other when in their nestedcondition may be controlled by varying the height of one or moretertiary props 23.

In one configuration, the top panel of the deck is of a plasticmaterial. This may be compression formed, vacuum formed, or injectionmoulded, as examples. The primary props preferably define the primarydepressions and the secondary props define the secondary depressions.

The pallet 1 as described above may but need not necessarily compriseprops or depressions as described above. The pallet 1 may be of a simpleconfiguration as shown in FIGS. 13C and 13D without any props ordepressions. As shown in FIGS. 13 C and 13D, the pallet 1 may comprise adeck 10 with chassis 110 located below the deck 10 for supporting thedeck 10.

Not relying on a twin deck construction, the single deck pallet 1 of thepresent invention as seen in FIGS. 13A, 13B, 13C and 13D gains strengthfrom the frame or chassis 110 of metal beams 112. One example of chassis110 is also shown in FIG. 16 that is a top view of the chassis 110 andFIG. 17 that is a bottom view of the chassis 110. The chassis 110 ofmetal beams primarily provide the load bearing capacity of the pallet1/deck 10. When the pallet 1/deck 10 is for example edge supported alongeither the first pair of sides 13 or second pair of sides 14, beams ofthe chassis 110 extending across the gap between the rails, act inbending to carry the load on the pallet. The number of beams and theirsecond moment of inertia in bending in such a manner are hence primarydesign factors.

In the preferred form the pallet 1 comprises of a deck of parallel beamsextending in a first direction (i.e. from one of first opposed side 13to another of the first opposed side 13) and parallel beams extending ina second direction (i.e. from one of second opposed side 14 to anotherof the second opposed side 14) being perpendicular to the firstdirection. Preferably there are 4 beams extending in each direction asshown in FIGS. 13A-13D. Preferably the beams 112 are hollow beams ofconstant quadrilateral (e.g. rectangular or square cross sections) asshown in FIGS. 18A-18F. The beams 112 are at least positioned asintermediate beams meaning the beams 112 are spaced from the sides 13,14 and corners 113 of the deck/pallet. In other words, each of the beams112 may be spaced apart (or spaced) from each of the sides 13, 14 of thedeck 10 that is parallel to a longitudinal axis along which that beamextends. The beams 112 may also define or be located as perimeter beamsof the pallet 1.

The perimeter beams 111 shown in FIGS. 13A and 13C are purely optional.This is because the load is typically placed in the middle of the pallet1 and therefore it is the cross members/beams 112 that are located atthe middle/intermediate portion of the pallet 1/deck 10 which need to bestrong. As shown in FIGS. 13B and 13D, the chassis 110 compriseplurality of beams 112 running from or between the first pair of sides13 of the pallet 1/deck 10 and beams running between the second pair ofsides 13 of the pallet 1 and there is no perimeter beam 13 in the pallet1. Each of the beams 112 are preferably of a hollow quadrilateral crosssection (e.g. rectangular cross section) as seen in FIGS. 18A-18F.

The beams 112 extending between pair of sides 13 are preferable at rightangles to the beams extending between pair of side 14. The beams 112extending between pair of sides 13 are preferably also parallel to eachother. Similarly, the beams 122 extending between pair of sides 14 arealso parallel to each other as can be seen in FIG. 13A. Also, see FIGS.16 and 17 which shows only the chassis 110 without the deck 10. Asshown, the plurality of orthogonal beams 112 provides a grid formation(or grid) to act in bending to assist in pallet load support. By beinghollow quadrilateral in cross section (e.g. rectangular or square crosssection), the beams are oriented with vertical sidewalls 112A, 112A′facing perpendicular to the plane of the deck 10 and horizontalsidewalls 112B, 112B′ facing parallel to the plane of the deck 10. Thebeams 112 may be positioned/arranged and are of a shape andconfiguration so that they can receive forklift tines to allow thepallet to be lifted.

At an intersection (such as an intersection I) of two beams of the grid,a first of the two beams preferably has both its vertical sidewalls112A, 112A′ removed in order to allow a second of the two beams to passthrough the first beam. An example of such a beam is shown in FIGS.18A-E.

As shown in FIG. 18A, the beam 112 has both its vertical sidewalls 112A,112A′ and one of the two horizontal sidewalls (top horizontal sidewall112B) removed at the portion in which the beam 112 is configured tointersect with another beam. It will be appreciated that the tophorizontal sidewall 112B of the beam 112 is the horizontal sidewall thatis proximal to the deck 10 and bottom horizontal sidewall 112B′ is thewall that is distal to the deck 10 when the chassis 110 supports thedeck 10. By removing the top horizontal sidewall 112B and two verticalsidewalls a notch 150 is formed on the beam 112.

FIGS. 19A-B show how two beams with such notch arrangement can be joinedtogether to form a grid at each intersection I of beams 112 in thechassis 110. In FIGS. 19A-B, the first of the two beams is denoted byreference numeral 112′ and the second beam that passes through the firstbeam is denoted by reference numeral 112″. It will be appreciated thatthe second beam 112″ can be but need not of the same type as the firstbeam 112′. In other words, the second beam 112″ can be any suitable beamthat is capable to be received within the notch 150 formed on the firstbeam 112′.

Hence, from the above, it can be appreciated that at the intersection oftwo beams 112′, 112″ of the grid, a first 112′ of the two beams may haveboth its vertical sidewalls 112A as well as one of the horizontalsidewalls (top horizontal all 112B that is proximal to the deck) removedto provide the notch 150 that allows a second 112″ of the two beams topass through the first beam 112′.

Alternatively, it is possible that at the intersection of two beams112′, 112″ of the grid, a first 112′ of the two beams may have both itsvertical sidewalls 112A, 112A′ removed but the horizontal sidewalls(i.e. the top horizontal sidewall 112B that is proximal to the deck andthe bottom horizontal sidewall 112B′ that is distal from the deck) isleft unremoved and be continuous. Such configuration provides a slot 160to be formed at the first beam 112′ that allows a second 112″ of the twobeams to pass through the first beam 112″.

As shown in FIG. 18D, the beam 112 has both its vertical sidewalls 112A,112A′ removed at the portion in which the beam 112 is configured tointersect with another beam. However, both the top horizontal sidewall112B and the bottom horizontal sidewall 112B′ are not removed. It willbe appreciated that the top horizontal sidewall 112B of the beam 112 isthe horizontal sidewall that is proximal to the deck 10 and bottomhorizontal sidewall 112B′ is the sidewall that is distal to the deck 10when the chassis 110 support deck 10. By only removing the two lowervertical sidewalls, a slot 160 is formed on the beam 112.

FIG. 19C shows how with such a slot arrangement the two beams can bejoined together to form a grid at each intersection I of beams 112 inthe chassis 110. In FIG. 19C, the first of the two beams is denoted byreference numeral 112′ and the second beam that passes through the firstbeam is denoted by reference numeral 112″. It will be appreciated thatthe second beam 112″ can be but need not be of the same type as thefirst beam 112′. In other words, the second beam 112″ can be anysuitable beam that is capable to be received within the slot 160 formedon the first beam 112′.

It can be appreciated that by having such configuration, there is lesswelding needed of two right angled orientated beams 112 at thejunction/intersection of the grid. For example, at each grid orintersection/junction of two beams 112′, 112″, the welding may onlyoccur at the vertical sidewalls of the beams. Little or no welding mayoccur at the horizontal sidewalls of the beams at thejunction/intersection or the grid. In one configuration, welding mayoccur at the top horizontal sidewall on the beams. In one configuration,wielding may occur at top horizontal sidewall and vertical sidewalls ofthe beams, but no wielding may be required at the bottom horizontalsidewall 120B of the beams (see FIG. 20A). Since the bottom sidewall112B of the first beam 112′ continuous to support the second beam 112″,the second beam 112″ cannot fall even when no welding is applied to thebottom horizontal sidewall 120B of the beams 112′ and 112″.

This can be advantageous because since less welding is required at thejunction, risk of cracks being formed at the welded portion or any otherdamage that can typically occur at the wielded portion especially due tofatigue or due to load or overload of the pallet can be prevented oravoided completely. In particular the bottom horizontal sidewall 112B′of one of both of the beams at the intersection are continuous. Thismeans that the area of highest bending moment stress in a beam (at thebottom) both beams 112, 112″ have continuity of material. There is nodiscontinuity if the two beams 112′ and 112″ at the intersection were ina butting relationship where only one beam may have its bottomhorizontal sidewall continuous.

FIG. 20B shows load L being applied at the beam. The tension T occurs atthe bottom horizontal sidewall that supports the load. An example of astress and stain diagram of the beam is also shown in FIG. 20 B.

As shown in FIGS. 13A and 13C, the grid of metal beams may compriseperimeter beams 111 but as mentioned above such perimeter beams 111 arepurely optional. The perimeter beams 111 may meet at corners 113, thecorners 113 being either a right-angled corner or a chamfered corner.Chamfered corner as in the preferred form is shown in FIG. 13A-FIG. 13D.The corner may also be rounded. The chamfered construction at thecorners of the perimeter beams provides additional strength to thecorner regions of the pallet. The corner regions 113 may additionallycarry shock absorbing elements such as for example shown at the bottomleft hand corner in FIG. 13A showing shock absorber 114. The shockabsorber may be made of a rubber or plastic material.

In a one example, the perimeter beams 111 are of a C or U section shape.In the preferred form the region 116 of the C shaped perimeter beam 111is the outer most portion of the frame 110. The beams could also be boxor trapezoidal shaped.

Alternatively, and more preferably, the perimeter beams 111 may also beof a hollow quadrilateral cross section (e.g. rectangular cross section)similar to the beams 112. At the grid where perimeter beam 111 and beam112 intersect, either the perimeter beam 111 or beam 112 preferably hasboth its vertical sidewalls 112A removed in order to allow a second ofthe two beams 111, 112 to pass through the first beam. It is possiblethat at the intersection of two beams 111, 112 of the grid, one of thetwo beams 111, 112 preferably has both its vertical sidewalls 112A aswell as one of the horizontal sidewalls removed in order to allow asecond of the two beams to pass through the first beam. As mentionedabove, perimeter beams 111 are purely optional and in the most preferredembodiment preferably the pallet has no such perimeter beams 111.

FIG. 21A-E show another example of a chassis 210 that may be used or bepart of the pallet 1 as described above. FIG. 21A shows a bottomperspective view of the metal framework of the chassis 210 of the deckfor use in several embodiments of a pallet 1 as described above. FIG.21B is a bottom plan view of the chassis of FIG. 21A. FIG. 21C shows aview in direction XX of the chassis of FIG. 21B, FIG. 21D shows a viewin direction YY of the chassis of FIG. 21B. FIG. 21E is a top plan viewof the chassis of FIG. 21A.

As shown, the plurality of orthogonal beams 212A-212L provides a gridformation to act in bending to assist in pallet load support.

FIGS. 22A-22F show detailed views of various sections of FIGS. 21B and21E. Specifically, FIG. 22A shows a detailed view of section C of FIG.21B. FIG. 22B shows a detailed view of section D of FIG. 21B. FIG. 22Cshows a detailed view of section E of FIG. 21B. FIG. 22D shows adetailed view of section F of FIG. 21B. FIG. 22E shows a detailed viewof section G of FIG. 21E. FIG. 22F shows a detailed view of section H ofFIG. 21E. FIG. 22G shows a cross-sectional view along direction VV ofFIG. 21C. FIG. 22H shows a cross-sectional view along direction ZZ ofFIG. 21E. In FIGS. 22A-22F welded portions W are also shown. The weldedportions W are shown just as an example. The chassis of FIGS. 21A-E neednot be welded in the exactly the same manner as shown in FIGS. 22A-F andlesser welding than what is shown in FIGS. 22A-F are equally possible.

FIGS. 23A-23D show how beams 212A-212H may look like. Specifically, FIG.23A shows a perspective view of one of the beams (although labelled as212A, it may be any one of the beams 212A-212H). FIG. 23B shows an endview of the beam 212A of FIG. 23A. FIG. 23C shows a top plan view of thebeam 212A of FIG. 23A. FIG. 23D is a side view of the beam of FIG. 23A.

Similarly, FIGS. 24A-24D show how beams 212I-212L may look like.Specifically, FIG. 24A shows a perspective view of one of the beams(although labelled as 212I, it may be any one of the beams 212I-212L).FIG. 24B shows an end view of the beam of FIG. 24A. FIG. 24C shows a topplan view of the beam of FIG. 24A. FIG. 24D is a side view of the beamof FIG. 24A.

As shown the beams 212A-212L may of hollow quadrilateral in crosssection (e.g. rectangular or square cross section). By being of suchcross section, the beams may be vertical sidewalls 213A, 213B, 213C,213D facing perpendicular to the plane of the deck 10 and horizontalsidewalls 215A, 215B, 215C, 215D facing parallel to the plane of thedeck 10.

The beams 212A-212L may be positioned/arranged and are of a shape andconfiguration so that they can receive forklift tines to allow thepallet to be lifted.

As shown in FIG. 24A, at an intersection (such as an intersection J) oftwo beams of the grid, a first of the two beams preferably has both itsvertical sidewalls 213C, 213D removed in order to allow a second of thetwo beams to pass through the first beam. Also as shown in FIG. 24B, thebeam 2211 may have both its vertical sidewalls 213C, 213D and one of thetwo horizontal sidewalls (top horizontal sidewall 215C) removed at theportion in which the beam 112 is configured to intersect with anotherbeam (which is preferably any one of beams 212E-212H). It will beappreciated that the top horizontal sidewall 215C is the horizontalsidewall that is proximal to the deck 10 and bottom horizontal sidewall215D is the wall that is distal to the deck 10 when the chassis 210supports the deck 10. By removing the top horizontal sidewall 112B andtwo vertical sidewalls a notch 250 is formed on the beam 212I, 212L.

FIG. 22C shows how two beams with such notch arrangement can be joinedtogether to form a grid at each intersection J of beams 212E-212L in thechassis 210.

It can be appreciated that by having configuration as described above,there is less welding needed of two right angled orientated beams212E-212L at the junction/intersection of the grid. The detailed viewsof FIGS. 22A-22F shows an example of where the wielding W may berequired. Preferably the welding may only be required at each grid orintersection/junction of two beams. The welding may only occur at thevertical sidewalls of the beams. Little or no welding may occur at thehorizontal sidewalls of the beams at the junction/intersection or thegrid.

Due to less welding required at the junction, risk of cracks beingformed at the welded portion or any other damage that can typicallyoccur at the wielded portion especially due to fatigue or due to load oroverload of the pallet can be prevented. The corners may be L shaped asshown in FIGS. 21A-E. The corner may comprise corner brackets 217. FIG.25 shows an example of a corner bracket that may be welded (see FIG. 22Awhere welded regions are shown by W) or otherwise attached to eachcorner of the chassis. regions 217 may additionally carry shockabsorbing elements such as a shock absorber. The shock absorber may bemade of a rubber or plastic material.

Therefore, from the above it will be appreciated that the pallet 1 ofthe present invention may comprise a deck/pallet deck for receiving theload thereon and a chassis 110, 210 (such as shown in FIGS. 16,17,21A-21E) below the deck 10 for supporting the deck 10. The deck having atop portion 118 for supporting the load and a bottom portion oppositethe top portion, at least four sides, the at least four sides comprisinga first pair of opposed sides 13 and a second pair of opposed sides 14.The chassis 110, 210 is in a grid formation as shown in FIGS. 16,17,21A-21E. As shown, the chassis 110, 210 comprises a first set of atleast two spaced apart and parallel beams extending between the firstpair of opposed sides of the deck but spaced apart from the second pairof opposed sides of the deck. Also, as shown in FIGS. 13D-13D, 16 17,21A-21E, a chassis 110, 210 also comprises a second set of at least twospaced and parallel beams extending between the second pair of opposedsides of the deck but spaced apart from the first pair of opposed sidesof the deck. The first set of beams are orthogonal to the second set ofbeams. At each intersection of two beams of the grid a first of said twobeam has a notch 150, 250 or a slot 160 to allow a second beams to passthrough the first beam.

In the preferred form all of the beams 112,212A-212L are co-planar. Inthe preferred form all of the beams 112, 212A-212L are of the sameheight so as together, to define the bottom 12 of the deck 10. Thebottom portion 12 of the deck is hence of a planar (though adiscontinuous grid of beams) configuration allowing for forklift tinesto support the deck at the bottom surface.

The frame/chassis 110, 210 is optionally enveloped by a plastic. Theplastic may define the top panel 118 that defines the top 11 of thepallet 1. In the preferred form the plastic may also extend about theperimeter of the perimeter beams and also over the bottom of the beamsto define the bottom of the pallet 1. The plastic envelope of the framemay be provided of at least two parts of plastic that are bondedtogether. The primary part defining the top panel 118 and props and theadditional part or parts being plastic received by the frame from below.The top panel may be made from a fibre reinforced plastic. The top panelmay be adapted and figured to help keep the beams in column duringbending rather than deviating laterally during bending.

Alternatively, the plastic may merely define the top panel 118 and theprimary and secondary props 15, 16, the frame 110 being secured orotherwise bonded to the plastic.

In some forms the plastic may be compression moulded about the beam grid110 or injection moulded about the beam grid.

The top panel is where goods or a load is supported on the pallet. Theload may be evenly distributed across the beams. However, in manysituations, a pallet may have an uneven load distribution. In addition,a pallet may be picked up by the tines of a forklift in a manner tocause an uneven load distribution and point loading of the tines of aforklift on the bottom of the deck. In addition, forklifts may hit thesides of the deck as speed and this may cause damage to the pallet.

With reference to FIG. 15a it can be seen that when a forklift picks upa pallet 1 the tines 100 of a forklift may contact the bottom of thedeck 10 (i.e. the bottom of the beams of the deck) in a manner to createa point load as seen in FIG. 15a . This point load L on beam or beams112,212A-212L may result in the creasing or crushing of the wall of thebeam 112, 212A-212L at the bottom of the deck. One way to avoid thispoint loading damaging the bottom of the beam, thereby potentiallydecreasing the strength of the pallet, is to increase the gaugethickness of the beam 112, 212A-212L. However, increasing the gaugethickness increases the weight of the beam or beams and hence then theweight of the pallet. Given that the most likely location for liftingmode damage to occur by a forklift is to the beams 112, 212A-212L at thebottom region of the beams, it has been found that enhancing thestrength of the beams at the bottom region is able to be achievedwithout substantially increasing the weight of the beams 112,212A-212L.

The beams 112, 212A-212L are still able to be manufactured from a thingauge cold rolled steel sheet yet provide enhanced resistance tocreasing/bending due to tine point loading where it is needed such as byan engineered wall profile such as region 130, 230 as seen in FIGS.18A-18E, 23B, 24B at the bottom surface 131, 231 of the bottom sidewall1126′, 2156, 215D. The engineered profile at region 130, 230 is forexample an internal flange extending into the hollow section of therectangular cross sectioned beam as seen in FIGS. 18A-18E, 23B and 24B.The engineered profile enhances the second moment of inertia of thebottom of the beam and as a result enhances the resistance of thisregion of the beam to creasing damage or impact damage resulting fromfor example point loading of the end of a forklift tine on the bottom ofthe beam. In other words, the beams 112, 212A-212L may remain of a thingauged steel but may have a form at the bottom region for enhancing thestrength at the bottom region. This allows for the beams 112, 212A-212Lto still remain of a low weight given that such enhanced strengthformations are not required in other parts of the beams.

In alternative forms the strength of the bottom of beams 112, 212A-212Lmay be enhanced by forming the thin gauged sheet in a way so as todouble the layers of the sheet at the bottom surface.

Likewise, the perimeter beams (if present) may have a doubling of sheetmetal at the bottom to also help resist impact damage of the perimeterbeams at the bottom. Hence forming the sheet metal to define the beamsin a matter to enhance localised strength of the beams can be achievedinstead of enhancing the thickness of the gauge of sheet metal used toform the entire beam, thereby providing weight savings.

The doubled region of the beam preferably extends along the entirelength of the beam. But in an alternative configuration, the doubledregion may be provided intermediate of the ends of the beam yet stillprovide enhanced bend resistance.

As discussed above forklift tines 100 are able to reach under the deck 1at locations between the primary props 15. The horizontal spacingbetween the primary props 15 is such as to allow for sufficientwidth-wise clearance between props for a tine of the forklift.

To ensure that forklift tines (typically 100 mm wide) contact the bottomof the pallet at where the beams 112 are provided (beams 112 extendingin the fork-wise direction) are preferably located between the gapsbetween the primary props. A gap G can be seen in FIG. 13 for a forklifttine 100 (of FIG. 13E) to pass through. The forklift tine 100 will cometo bear on the beam(s) 112. When the pallet is for example stored on theground, with the primary props supporting the pallet on the ground, theonly gap for forklift tines to pass under the deck is at the gap or gapsbetween adjacent primary props. Given that forklift tines are typicallyof a width W of 100 mm wide, the gap G between primary props and thepositioning of the beam(s) 112 in the gap is preferably such that theforklift tine is always going to come into contact with a beam 112 orwhere provided both or multiple beams 112 extending between a gap G ofadjacent primary props.

In one example, the distances K are preferably less than 100 mm so thatif a forklift tine abuts against a primary prop, at its other side thetine sits under the beam 112. Likewise, the distance K2 between beamsmay be less than 100 mm so that a forklift tine cannot slip between thegap between the parallel intermediate beams as shown in FIG. 13. In oneexample, for example the spacing K and K2 is about 70 mm. Likewise, thespacing may be such in the other direction but has not been described indetail but will be appreciated by a person skilled in the art how thiswould work in order to ensure that a forklift tine reaching under a deckof a pallet will always come to bear on an intermediate beam of thepallet. The spacing on the other axis may be different as to the axis asshow.

It will be appreciated that in FIG. 13E only one forklift tine is shownhowever two forklift tines are usually used for lifting a pallet, theother forklift tine entering the gap adjacent to the gap describedabove. As mentioned above forklift tines can also reach below the deckin a direction lateral to the direction shown in FIG. 13 between gaps ofadjacent primary props spaced in the other direction.

The pallet of the present invention may be able to be made of a lightweight construction. This helps reduce shipping/return costs. It alsoallows the pallet to be handled by hand. As an example, some weights ofpallets that are able to be edge supported and able to support an evenlydistributed load of 2500 kg may be as follows:

-   -   (a) 1200×800—around 18 kg    -   (b) 1200×1000—around 22 kg.

The pallets may nest to around 50% or better of their height creatingfurther savings on return shipping costs.

The deck of the pallet primarily defined by the height of the metalframe/chassis plus plastic may be between 30 and 60 mm in height.

The use of a thin gauge metal sheet, preferably cold rolled into thedesired beam shape preferably allows for at least one of theintermediate beams and perimeter beams to remain of a light weightconstruction yet have localised reinforcing (such as by providing anengineered profile and/or a doubling up of the layers of the sheet metalat certain locations) to improve impact/crease resistance. In thepreferred form the steel gauge used is preferably between 0.045 to 1.8mm in thickness. Preferably the sheet gauge is 1 mm in thickness.Examples of dimensions and other characteristics of example profilesthat can be used for the perimeter and/or intermediate beams is shownbelow.

The beams 112, 212A-212L may be made from a single sheet, or two sheetsof half the profile each, of cold rolled steel, formed into a box shapewith either continuous or spot welds joining the 2 ends of the sheetwhere required. Parameters:

TABLE 1 Preferred Profile Steel type Cold rolled Range of strengthsCoated or not coated Std or high tensile Steel gauge 0.045 mm to 1.80 mmHeight of box section 10 mm-60 mm Top width 5 mm-80 mm Length of downturns 0 mm - 60% of height of I-beam Length of up turns As with downturns (not shown). NOTE: If up turns are present, do not necessarilyneed to have down turns and vice versa. Bottom Width 5 mm-80 mm WeldingStitch or continuous weld along bottom seam, such that the two halves onthe bottom are held together when under load. Example dimensions a = 38mm b = 30 mm c = 18 mm d = 18 mm e = 4

Load distribution has potentially a much more detrimental effect onperformance of the pallet than the quantum of the load. As seen in FIG.15B a pallet having a centrally applied load between each side supports(such as the rails 19 of the rack) will result in a substantially evenbend profile of the beams of the deck extending between the rails.However as seen in FIG. 15B an uneven load distribution of a pallet mayresult in an uneven bend profile and as a result a higher curvature R1at and/or near one of the rails 19 compared to R2 at or near the otheropposite rail. The higher curvature R1 (even though the load L in FIG.15A may be the same as the load L in FIG. 15B) can result in goodsstacked on the pallet from toppling more readily in region R1 given theslope of region of the top of the pallet on which the goods are sittingon. Hence in designing the pallet it is important to take account ofuneven load distribution and ensuring that the beams are sufficientlyrigid to not either bend to failure or result in a significant slope ofthe top of the pallet being established which could potentiallydestabilise the goods on top. The goods may also also crush ontothemselves due lean that they may be on.

It will hence be appreciated that the design of the pallet as describedabove may achieve a good and desirable outcome for carrying loads of upto two tonnes on the pallet and hence having sufficient strength yetable to be nested by virtue of a decrease in the thickness of the deckand/or not by providing a twin deck format. In addition, the tensionbetween weight of the pallet and the strength of the pallet is alsosuitably provided uncompromised. The pallet is sufficiently strong yetis sufficiently light to be handled by hand. In addition, the pallet isable to handle a substantial degree of wear and tear and potentialdamage from for example forklift tines.

Whilst herein described are pallets such as a shipping pallet comprisingof a deck and primary props and preferably secondary props it will beappreciated that the deck is also able to be used as part of a shippingcrate such a crate comprising of a deck as herein described andsidewalls extending vertically above the deck. The sidewalls may definean enclosure/crate within which goods can be stored. The sidewalls mayalso assist in load transfer of a plurality of like stacked crates fromone pallet to the other at the edges of the deck rather than via propsthat are located intermediate of the footprint of the crate.

The invention herein described also comprises a system of nesting singledeck pallets as herein described in combination with standard rackingand preferably also drive through racking. It will be appreciated thatthe pallets that have herein been described can lend themselves for usein standard and/or drive through racking.

The pallet of the present invention is preferably made of non-biomaterial. The pallet is preferably made from plastic and metal.

The pallet is preferably a four-way pallet allowing fork entry from foursides of the pallet. Preferably the entry ports (the gaps) betweenadjacent primary props are the same height at all sides based on thefact that the primary props extend an equal distance from the deck.

The optional perimeter frame can be provided to facilitate the storageof the rack in drive through racking. The ledge at the exterior of twoparallel sides of the deck, outside of the primary props, allows fordrive through racking of the pallet. And again, working in conjunctionwith the props being spaced approximate to the rails of the drivethrough racking will help hold the pallet on the rails of the drivethough racking and prevent the pallet from sliding off the racking.

The props and corners may be replaced if damaged.

Where in the foregoing description reference has been made to elementsor integers having known equivalents, then such equivalents are includedas if they were individually set forth.

Although the invention has been described by way of example and withreference to particular embodiments, it is to be understood thatmodifications and/or improvements may be made without departing from thescope or spirit of the invention.

1. A pallet for carrying a load and is able to be lifted by tines of a fork lift, the pallet comprising a planar deck for receiving a load thereon and a chassis below the deck for supporting the deck, the chassis comprising a plurality of hollow beams of constant quadrilateral cross section in a grid formation to act in bending to assist in pallet load support, the beams spanning parallel to the plane of the deck and each oriented with vertical side walls facing perpendicular to the plane of the deck and horizontal side walls facing parallel to the plane of the deck, wherein at intersections of two beams of the grid a first of said two beams has both of its vertical sidewalls removed to allow a second of said two beams to pass through the first beam.
 2. The pallet as claimed in claim 1, wherein the beam with the sidewalls removed at the intersection has at least some of its bottom horizontal sidewall continuous over the intersection and is parallel and adjacent, and touches the bottom horizontal sidewall of the beam that passes through the first mentioned beam.
 3. The pallet as claimed in claim 1, wherein the beam with the sidewalls removed at the intersection has at least some of its top horizontal side wall continuous over the intersection and is parallel and adjacent, and touches the top horizontal side wall of the beam that passes through the first mentioned beam.
 4. The pallet as claimed in claim 1, wherein the beam that passes through the first mentioned beam has no cut-outs across of adjacent the intersection.
 5. The pallet as claimed in claim 1, wherein the beam that passes through the first mentioned beam is of a constant cross section across and adjacent the intersection.
 6. The pallet as claimed in claim 1, wherein the beam that passes through the first mentioned beam is welded to the first mentioned beam at regions where sidewalls of the two beams are adjacent each other.
 7. The pallet as claimed in claim 1, wherein the pallet is a shipping pallet.
 8. A pallet as claimed in claim 1, wherein the grid is provided of at least two first set of said beams extending between a first pair of opposed sides of the deck and at least two second set of said beams extending between a second pair of opposed sides of the deck.
 9. The pallet as claimed in claim 8, wherein at least one of the first and second set of beams define a bottom portion of the deck at where the tines of the forklift is able to engage to lift the pallet.
 10. The pallet as claimed in claim 1, wherein a bottom of at least one of the beams is provided with at least one of (a) an engineered profile (b) a double wall of said sheet material.
 11. The pallet as claimed in claim 10, wherein the engineered profile and/or the double wall of said sheet material is provided in a manner to increase bend resistance at the bottom of the beam.
 12. The pallet as claimed in claim 10, wherein the engineered profile and/or the double wall of said sheet material is provided in a manner to increase second moment of inertia at the bottom of the beam.
 13. The pallet as claimed in claim 10, wherein the beams of at least one of the first and second set of beams are quadrilateral in cross section and the engineered profile is a flange of said sheet metal extending into the interior or the beam.
 14. The pallet as claimed in claim 10, wherein the beams comprise of both a single ply of said sheet material wall construction and double ply of said sheet material wall construction. 15.-23. (canceled)
 24. A pallet for carrying a load and is able to be lifted by tines of a forklift, the pallet comprising a planar deck for receiving the load thereon and a chassis below the deck for supporting the deck, the deck having a top portion for supporting the load and a bottom portion opposite the top portion, at least four sides, the at least four sides comprising a first pair of opposed sides and a second pair of opposed sides, the chassis being in a grid formation and comprising a first set of at least two spaced apart and parallel beams extending between the first pair of opposed sides of the deck but spaced apart from the second pair of opposed sides of the deck, and a second set of at least two spaced and parallel beams extending between the second pair of opposed sides of the deck but spaced apart from the first pair of opposed sides of the deck, wherein the first set of beams are orthogonal to the second set of beams, wherein at each intersection of two beams of the grid a first of said two beam has a notch or a slot to allow a second beams to pass through the first beam.
 25. The pallet as claimed in claim 24, wherein the beams are hollow beams of constant quadrilateral cross section, the beams spanning parallel to the plane of the deck and each oriented with vertical sidewalls facing perpendicular to the plane of the deck and horizontal sidewalls facing parallel to the plane of the deck.
 26. The pallet as claimed in claim 24, wherein the notch or the slot is formed by removing both the vertical sidewalls of the said first beam.
 27. The pallet as claimed in claim 24, wherein the slot is formed by removing both of its vertical sidewalls removed and one of the horizontal sidewalls of said first beam, one of the horizontal sidewalls being proximal to the deck.
 28. A single deck pallet comprising: a deck having a top portion for supporting a load and a bottom portion opposite the top portion, at least four sides, the at least four sides comprising a first pair of opposed sides and a second pair of opposed sides, the bottom portion comprising a chassis, the chassis comprising a plurality of orthogonal hollow beams of constant quadrilateral cross section in a grid formation to act in bending to assist in pallet load support, the beams spanning parallel to the plane of the deck and each oriented with vertical sidewalls facing perpendicular to the plane of the deck and horizontal sidewalls facing parallel to the plane of the deck, wherein at intersections of two beams of the grid a first of said two beams has both of its vertical sidewalls removed to allow a second of said two beams to pass through the first beam.
 29. The pallet of claim 28, wherein the grid formation is provided of at least two first set of said beams extending between the first pair of opposed sides of the deck and at least two second set of said beams extending between a second pair of opposed sides of the deck. 30.-50. (canceled) 